3D Printed Zirconia Ceramics via Fused Deposit Modeling and Its Mechanical Properties

doi:10.15541/jim20200560

Abstract

Abstract:

Dense and porous zirconia ceramics were 3D printed with granular feedstock and screw extrusion mechanism on the basis of the traditional fused deposition method. The printability of granular feedstock, microstructure of the body and mechanical properties of ceramic materials were studied. The unsupported structure with maximum inclination 165° and span 5.5 mm were obtained. Effects of the two filling modes of printing on the flexural strength and Weibull modulus of the dense zirconia ceramics were compared. The results showed that the “single line+rectangle” filling mode was more conducive to achieve higher density and better mechanical properties than the traditional single line filling mode. Materials with bending strength of 637.8 MPa and Weibull modulus of 9.1 were obtained. The compressive behavior of porous zirconia ceramics prepared with different porosities were studied, showing an exponential law between compressive strength and porosity. There was only elasticity stage on the stress-strain curve for the samples with high porosity, while collapse stage may appear for the samples with low porosity. There was no collapse stage for both samples.

Key words: fused deposit modeling, 3D printing, zirconia ceramic, porous ceramic

CLC Number:

TQ174

ZHANG Li, YANG Xianfeng, XU Xiewen, GUO Jinyu, ZHOU Zhe, LIU Peng, XIE Zhipeng. 3D Printed Zirconia Ceramics via Fused Deposit Modeling and Its Mechanical Properties[J]. Journal of Inorganic Materials, 2021, 36(4): 436-442.

Figures/Tables 7

Fig. 1 Printing path for sample preparation (a) Single line pattern; (b) “Single line + rectangle” pattern; (c) Porous ceramic

Fig. 2 Rheology and printability of the feedstock (a) Viscosity at various shear rate at 170 ℃; (b) Schematic diagram of the extrusion mechanism; (c) Unsupported structures with different inclinations; (d) Unsupported structures with different spans

Fig. 3 SEM images of the printed green body and sintered ceramics (a) Surface of the green body and partial enlarged SEM image; (b) SEM image of fracture surface of green body; (c) Partial enlarged SEM image of Fig. 3(b); (d) Surface of the sintered part and partial enlarged SEM image; (e) SEM image of fracture surface of sintered part; (f) Partial enlarged SEM image of Fig. 3(e)

Fig. 4 3D printed dense zirconia ceramics (a) Surface of single line filling mode; (b) Surface of “single line+rectangle” filling mode; (c) Densities of the printed green bodies and sintered ceramics; (d) Printed and sintered rectangular bar; (e) Sintered 3D Chinese letters; (f) Sintered dental ceramics, turbine rotor and impeller

Fig. 5 (a) Flexural strength of printed green body and sintered ceramics; (b) Weibull modulus of the flexural strength

Fig. 6 3D printing porous zirconia ceramics (a) Picture of zirconia porous ceramics; (b) Enlarged view of pore structure; (c) Microstructure of the intersection area of the printing path; (d) Microstructure of the fracture surface of the pore walls

Fig. 7 Mechanical properties of porous ceramics (a) Compressive strength vs porosity; (b) Stress-strain curves of the porous ceramics with different porosities

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